Pneumatic Sheet Bending Bend Removing Machine.docx

PNEUMATIC SHEET BENDING AND BEND REMOVING MACHINE A PROJECT REPORT Submitted By H.PRAKASH

(111816114339)

S.PADMANABAN

(111816114338)

T.V.KULOTHUNGAN

(111816114324)

B NAVEEN SAGAR

(111816114336)

In partial fulfillment for the award of the degree Of

BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING RVS PADMAVATHY COLLEGE OF ENGINEERING & TECHNOLOGY CHENNAI ANNA UNIVERSITY CHENNAI 600025 APRIL 2019

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE Certified that this

project report “PNEUMATIC SHEET BENDING AND BEND

REMOVING MACHINE” , is the bonafide work

B.NAVEEN SAGAR (111816114336)

who carried out the project work under my supervision.

SIGNATURE Mr. M.KISHOR M.TECH HEAD OF THE DEPARTMENT.

SIGNATURE Mr. M.KISHOR M.TECH GUIDE

Department of Mechanical Engineering

Department of Mechanical Engineering

RVS Padmavathy college of

RVS Padmavathy college of

Engineering and Technology,

Engineering and Technology,

Sethilpakkam, Gummidipoondi-601202.

Sethilpakkam, Gummidipoondi-601202.

Submitted for the project work and Viva-voice Exam held on __________________.

INTERNAL EXAMINAR

EXTERNAL EXAMINAR

ACKNOWLEDGEMENT We take tremendous pleasure in acknowledging the assistants of many erudite personnel whom we wish to recognize with dutiful respect and abundant gratitude with whose help and encouragement we were able to do this project.

We are greatly indebted to our beloved chairman Thiru Dr. K.V.KUPPUSAMY and Trustees Mr. C.S.SATISH and DR. U.VISHALKUMAR for acting as a chief support by providing us excellent infrastructure in our college. We are greatly indebted our beloved Principal Dr. T.VENKATAMUNI for his constant support and encouragement.

It is an immense pleasure for us to express our gratitude and heartfelt thanks to Mr. M.KISHORE, Head of the Department of Mechanical Engineering for his guidance throughout the project.

Our sincere thanks to our project guide Mr. M.KISHORE, Assistant professor for having extended their fullest co-operation and guidance. We also thank them for their constant support and patience. We also take this opportunity to thank all the staffs of our department for having encouraged us in completing this project successfully.

We also thank our parents for their unparallel love and moral support & finally the almighty for showering his generous blessings on us, without whom we would have not got this far.

CONTENTS CHAPTER

PARTICULARS

ACKNOWLEDGEMENT 1. SYNOPSIS 2. INTRODUCTION 3. SELECTION OF PNEUMATICS 4. COMPONENTS AND DESCRIPTION 5. DESIGN AND DRAWINGS 6. PRINCIPLE OF OPERATION 7. AIR LEAKS 8. PROCESS SHEET 9. MERITS AND DEMERITS 10. LIST OF MATERIALS 11. COST ESTIMATION 12. CONCLUSION

BIBLIOGRAPHY PHOTOGRAPHY

PAGE No.

CHAPTER-1 SYNOPSIS This report deals with design and fabrications of pneumatic multipurpose presses, which is used for fixing bearings of rotors in the shaft, bending and bend removing with the help of a compressor.

Initially the shaft is held between two fixtures; top of the bearing is freely located on the step in the shaft and the other one is placed on the bottom fixture. As one of the bearing (located on the shaft step) is compressed, both the bearings are inserted in the shaft simultaneously as the top fixture moves down words. Similarly bending and bend removing process also occurred.

CHAPTER-2 INTRODUCTION The pneumatic multipurpose press is used for fixing the bearings in the shaft by holding the shaft between two fixtures. One of the fixtures is movable and the other is fixed. The pneumatic multipurpose press is also used to remove the bend in the shaft and bend the shaft. The principle of operation is the same as the conventional simple press.

The

difference is only in the type of drive and the type of fixtures used. The following points reveals why we have to make use of this type of press Pneumatic multipurpose press reduces the manual work. This type of machine reduces working time.

By using this machine the bearings can be inserted in the various lengths of shat (up to 600mm).

CHAPTER-3 SELECTION OF PNEUMATICS Mechanization is broadly defined as the replacement of manual effort by mechanical power. Pneumatics is an attractive medium for low cost mechanization particularly for sequential or repetitive operations. Many factories and plants already have a compressed air system, which is capable of providing both the power or energy requirements and the control system (although equally pneumatic control systems may be economic and can be advantageously applied to other forms of power).

The main advantages of an all-pneumatic system are usually economy and simplicity, the latter reducing maintenance to a low level. It can also have out standing advantages in terms of safety.

CHAPTER-4 PNEUMATIC COMPONENTS AND ITS DESCRIPTION

The pneumatic bearing press consists of the following components to fulfill the requirements of complete operation of the machine. i.

Pneumatic cylinder

ii.

Hand operated valve

iii.

Flow control value

iv.

Regulator or pressure control valve

v.

Pressure gauge

vi.

Connectors and

vii.

Hoses

1. CYLINDER: The cylinder is a double acting cylinder one, which means that the air pressure operates alternatively (forward and backward). The air from the compressor is passed through the regulator which controls the pressure to required amount by adjusting its knob. A pressure gauge is attached to the regulator for showing the line pressure. Then the compressed air is passed through the directional control valve for supplying the air alternatively to either sides of the cylinder. Two hoses take the output of the directional Control valve and they are attached to two ends of the cylinder by means of connectors. One of the outputs from the directional control valve is taken to the flow control valve from taken to the cylinder. The hose is attached to each component of pneumatic system only by connectors.

CYLINDER TECHNICAL DATA: Barrel: It is made of cold drawn aluminimum honed to 25mm. Piston Rod: M.S. hard Chrome plated Seals: Nitrile (Buna – N) Elastomer End Covers: Cast iron graded fine grained from 25mm to 300mm Piston: Aluminium. Media: Air. Temperature Range: 0^c to 85^c Cushions: Adjustable standard of 400mm bore and above.

DIRECTIONAL CONTROL VALVE:

Technical Data: Size

: ¼”

Pressure

: 0 to 10 kg / cm2

Media

: Air

Working Principle: Double acting cylinder are controlled by 2 way 5 port two position valve as shown in the fig. This valve has one inlet port (P), two cylinder ports (A and B), and two exhaust ports (R and S). (See solenoid valve drawings)

In this position of the valve supply is directed to cylinder port no. A, with cylinder port B connected to exhaust port R. The air supply is connected to cylinder port B; with cylinder port A is connected to exhaust port R.

By operating the valve in two positions the cylinder piston can get the forward stroke to pressing operation and return stroke to retrieve the work.

(ii)

FLOW CONTROL VALVE:

(a) Technical Data:

Size

: ¼”

Pressure

: 0 to 10 kg / cm2

Media

: Air

( b ) Purpose: This valve is used to speed up the piston movement and also it acts as an one – way restriction valve which means that the air can pass through only one way and it can’t return back.

By using this valve the time consumption is reduced because of the faster movement of the piston.

(iv) REGULATOR (OR) PRESSURE CONTROL VALVE:

Specification: 1. Port size

:

¼” BSP

2. Port size for pressure gauge 3. Inlet pressure

: 1/8” BSP :

15 bar Maximum

4. Outlet pressure

:

0.5 to 7 bar

5. Flow capacity

:

650 NI/min*

6. Set pressure

:

6 bar

7. Pressure drop

: 1 bar

8. Mounting position

: Vertical

* Flow capacity at 7 bar pressure Pressure control valves may be designed to vary the pressure to a desired level within limits and to maintain it at certain level. The air is passed through the throttling orifice by adjusting its knob in the desired direction. By adjusting the knob we can get different pressure ranges so that the load applied by the piston can also be varied.

V. PRESSURE GAUGE: Technical data: Port size

:

Pressure range

1/8” BSP :

0 – 10 kg/cm2

Pressure gauges are usually fitted with the regulators. So the air pressure adjusted in the regulator is indicated by the pressure gauge and also the pressure indicated in the pressure gauge is the line pressure of the air taken to the cylinder.

(VI) CONNECTIORS: In our pneumatic system there are two types of connectors used; one is the hose connector and the other is the reducer. Hose connectors normally comprise an adapter (connector) hose nipple and cap nut. These type of connectors are made up of brass or Aliminium or hardened steel. Reducers are used to provide inter connection between two pipes or hoses of different sizes.

They may be fitted straight, tee, “V” or other configurations.

These

reducers are made up of gunmetal or other materials like hardened steel etc. (VII) HOSES: Hoses used in this pneumatic system are made up of polyrethane. These hoses can with stand at a maximums pressure level of 10 kg/cm2. The various sizes polyurethane tubes and its specifications are shown in the table 2.

TABLE 2

Code No.

Od X Id

Burst

Working

Min.

Standard Weight

(mm)

Pressure

Pressure

Bending

Length

(kgf/cm2) (kgf/cm2) Radius

(g/m)

(m)

(mm) PU4025

4 X 2.5

32

< 10

10

200

9

PU4329

4.3 X 2.9

30

< 10

12

200

9

PU6040

6X4

27

< 10

16

200

18

PU8050

8X5

32

< 10

22

100

38

PU8060

8X6

27

< 10

22

100

34

PU9565

9.5 X 6.5

28

< 10

27

100

52

PU1065

10 X 6.5

30

< 10

28

100

55

PU1080

11 X 8

27

< 10

28

100

47

PU1180

12 X 8

30

< 10

28

100

55

PU1280

12 X 8

28

< 10

37

100

78

PU1290

12 X 9

27

< 10

37

100

70

PU1296

12.6

X 30

< 10

39

100

82

9.6

CHAPTER-5 DESIGN AND DRAWINGS NOMENCLATURE DESIGN NO.:1 P Total load acting at the center of the plate, kgf L Distance between supports, mm E Young’s Modulus or modulus of elasticity, N/mm2 I Moment of inertia, mm4

DESIGN NO.: II S Slenderness ratio L Length of the pillar, cm R Least radius of the cross section d/4 for circular cross section, cm Pcr Critical load in buckling that would result in failure, kgf σc Ultimate compressive strength, kgf/cm2 K Factor for end condition.

DESIGN NO.:III d Internal diameter of the bearing, mm D External diameter of the bearing, mm B Thickness of the bearing, mm

I. DESIGN FOR PLATE FOR STABILITY IN DEFLECTION: Deflection

= Y = P / 48 E1

L

= 300 mm

E

= 2.08 x 10^5 N/mm^2 bd^3

(400) (30)^3

= ------ = --------------12

=

9 x 10^3 mm^4

12

Calculating the load on the plate (P):Maximum load acting at the

--- 430kgf (from the Manufacturers catalogue)

center of plate at 5Kg / cm^2 Maximum load acting at the center of Plate at 7kg / cm^2

430 x 7 =

--------------

= 602 kgf

5 Load distributed to the front half of The plate

602 = P = ---------2 = 301kgf

P = 3010 N => Deflection of plate at maximum

(3010)(300)^3(301kg) =ν

= ----------------------------------(48) (2.08 x 1065) (9 x10^5)

ν

= 9.04 x 10^3mm

This deflection is under the safe limit. So the design is safe.

II. DESIGN CALCULATIONS FOR THE PILLAR: CALCULATION FOR STABILITY IN BUCKLING Long and slender shafts, axially loaded, should be checked for stability in bucking. Rankine’s formula for calculation for stability in buckling should be used if the slenderness ratio ‘s’ is in the range of 0-100. We are know that, Slenderness ratio ‘s’

= L/R

Where, L

=

90cm

D R

4.2

= --------

=

--------------

4

1.05cm

4

90 => S

= ----------

= 85.71

1.05 As the slenderness ratio for the pillar is with in the range of 20 to 100, Rankine’s formula should be used for calculating the stability for buckling.

Rankine’s formulas for bucking:

Π

Pcr

=

d^2 σ

c/4

------------------------[L +k (L/R) ^2]

(Refer page 171: machine tool design hand book) Where “K” depends upon the material and condition. For steel k = 1/25000 for both ends of column fixed. D

= 4.2cm

σ c = 22090 kgf/cm^2 L

= 90cm

R

= 1.05cm

Π (4.2) ^2 x (2200/4) Pcr

= -------------------------------90 + 1/25000(90/10.5) ^2

30479.723 Pcr

= ---------------

90.29 Pcr

= 337.58 kgf. For the pillar based on its material and dimensions, the critical load for bucking that

would result in failure is calculated to be 337.58 kgf. But as only a maximum load of 150.5 kgf is applied on each pillar while working, the design is safe.

III. MINIMUM CLEARANCE CALCULATION FOR INSERTING BEARINGS: Selecting a PSG 3hp T.E.F.C motor, the bearing and shaft sizes at driving and nondriving ends are detailed below:

DRIVING END: (SKF) Bearing: Brg. No.

=

6306

d

=

30mm

D

=

72mm

B

=

19MM

Tolerance =

(refer page 4.14 D.D)

-10 microns

Shaft: Size

=

30j6 (From component drg.)

=

30+0.009

NON DRIVING END

Bearing: Brg. No. =

6305

d

=

25mm

D

=

62mm

B

=

17mm

Shaft: Size = 25j6 = 25+0.009 To get the minimum clearance between the shaft and bearing, the shaft and bearing should be of their maximum and minimum sizes respectively.

DRIVING END: Minimum size of bearing = 30.000-0.01 = 29.99mm Maximum size of shaft

= 30.000+0.009

= 30.009mm

=> Clearance between shaft and Bearing = 30.009 29.990

(-)

----------------00.019mm ----------------Minimum clearance

= 0.019mm

NON – DRIVING END Minimum size of bearing

= 25.000-0.01 = 24.99mm

Maximum size of shaft

= 25.0000.0009 = 25.009mm

Clearance between shaft and Bearing = 25.009 24.990 -------00.019 -------Minimum clearance

= 0.019mm

Clearance of driving end + clearance of non driving end Mean clearance = ---------------------------------------------------------------------2

0.019 + 0.019 = --------------------------------2 Mean clearance = 0.019mm

For the maximum size of the shaft and bearing for which the machine is designed the minimum mean clearance (between the shaft and the bearing) is calculated to be 0.019 mm or 19 micros. Even though the fit is a clearance one, the bearing cannot be mounted on the shaft by hand force and also hammering would result in reduced life of the bearing. So, a constant force should be applied for which the machine is designed to perform.

1. Double acting pneumatic cylinder Technical Data Stroke length

:

Cylinder stoker length 160 mm = 0.16 m

Piston rod

:

18 mm = 18 x 10ˉ³ m

Quantity

:

2

Seals

:

Nitride (Buna-N) Elastomer

End cones

:

Cast iron

Piston

:

EN – 8

Media

:

Air

Temperature

:

0-80 º C

Pressure Range

:

8 N/m²

2. Flow control Valve Technical Data Port size

:

0.635 x 10 ֿ² m

Pressure

:

0-8 x 10 ⁵ N/m²

Media

:

Air

Quantity

:

1

Max working pressure

:

10 x 10 ⁵ N/m²

Temperature

:

0-100 º C

Fluid media

:

Air

Material

:

Brass

Max pressure

:

10 x 10 ⁵ N/m²

Outer diameter

:

6 mm = 6 x 10 ˉ ³m

Inner diameter

:

3.5 mm = 3.5 x 10 ˉ ³m

3. Connectors Technical data

4. Hoses Technical date

CHAPTER-6 PRINCIPLE OF OPERATION The pneumatic multipurpose press is used for fixing bearings in the shaft up to a length of 600mm. In the pneumatic multipurpose press the main thing being the pressure developed is done with the help of a compressor. The air in that compressor is passed to the double acting cylinder through the control valves. There are two control valves used in this press. One is pressure control valve or regulator and another one is the flow control valve. When the compressed air is passed to the pressure control valve, the required pressure is obtained by adjusting its knob. When the air is passed to the flow control valve, the speed of movement of piston is controlled by adjusting the knob. The cylinder piston rod is connected to the top fixture. A bottom fixture is fixed on the bottom plate by using ‘T’ bolts or hexagonal bolts and nuts.

Bearing inserting procedure: First one of the bearings is placed on the bottom fixture. Then the shaft is taken and the other bearing is kept ion the step in the shaft. When the shaft is kept vertically on the bottom fixture some portion of the shaft goes inside the bottom fixture. At the same time the compressor is loaded to get the pressure required and the hand operated valve is manually actuated from the neutral position to the input position to move the piston. The top fixture in the piston had inserted to its required position rod pushes the bearing which is placed on the shaft.

When the bearing had inserted to its required position, there will not be any further down ward movement; at the same time the entire shaft will move downward so that the another bearing placed on the bottom fixture also gets inserted. Then the valve is brought to the output position in which the air moves the piston upward and the shaft is removed.

Bearing Removing procedure: The shaft is kept vertically between the bottom fixture and top fixture. The bearing which is removed is in the top of the fixture. The remaining portion of the shaft touches the bottom fixture.

At the same time the compressor is loaded to get the pressure required and the hand operated valve is manually actuated from the neutral position to the input position to move the piston. The top fixture in the piston had inserted to its required position rod pushes the bearing which is placed on the shaft. When the bearing had removed to its required position, there will not be any further down ward movement. Then the valve is brought to the output position in which the air moves the piston upward and the shaft is removed.

CHAPTER-7 AIR LEAKS

Air leaks are not hazardous, but they can be extremely waste full of power. In a typical system as much as 10% of the power requirements at any period can be made up of air leaking to waste.

Air loss and power wastage by air leaks

* Two stage compression

Sheet No. Part Name Se

Operation

q.

details

: 1 : BOTTOM & TOP PLATE

Total Time

: 1080 min.

Machin

Setting

Speed

Feed

No.

Machining

e

Time

(rpm)

Mm/r

of

Time

ev

cots

(min)

-

-

-

No

(min)

Tools

Gauges

Rem ark

. 1

Chucking

Lathe

16

-

Chuckke y

2

Facing

Lathe

20

120

0.5

4

45

Surface

-

gauge Facing

Vernier

-

Meter

-

tool 3

Turning

Lathe

12

120

0.5

4

30

R.H. tool

Scale 4

Reversing The

Lathe

30

Chuckke

job & chucking 5

Facing

y Lathe

20

-

-

-

-

120

0.5

4

45

Surface

-

gauge Facing

Vernier

-

Meter

-

tool 6

Turning

Lathe

12

120

0.5

4

30

R.H. tool

Scale 7

Changing the job to another M/C

8

Fixing on the table

40 Milling

10

Chuckke -

-

-

-

y

-

-

-

-

-

-

Spanner

-

-

Plain

Meter

-

milling

Scale

M/C

‘T’ bolt & Nut

9

Milling

Milling M/C

10

125

1

3

90

cutter 10

Reversing The job & fixing

11

Milling

Milling

15

M/C Milling

10

-

-

-

-

Spanner

-

-

125

1

3

90

End mill

Meter

-

Cutter

Scale

‘T’ slot

-

-

-

-

-

-

-

-

M/C 12

‘T’ slot

Milling

20

80

0.5

4

295

M/C 13

Changing the job

Drilling

to another M/C

M/C

cutter 30

& fixing

-

-

-

-

Spanner ‘1’ bolt & nut

14

Drilling Dia. 43mm

15

Drilling Dia. 30mm Material

Drilling

40

M/C

Drilling

20

Drill bit 100

0.5

1

100

100

0.5

1

50

M/C : C15

Quantity

: 1

Drill bit

Sheet No.

:2

Seq.

Operation Machine Setting Speed Feed

No.

details

time

(rpm) mm/rev of

(min) 1

chucking

Lathe

3

No.

-

-

Machining Tools

Gauges

Remarks

Surface

-

time

cuts

(min)

-

-

chuckkey

gauge 2

facing

lathe

2

500

2

3

10

Facing tool

vernier

-

3

turning

lathe

2

500

2

4

5

R.H. tool

Vernier

-

4

Reversing lathe

5

-

-

-

-

chuckkey

Surface

-

the job &

gauge

chucking 5

facing

lathe

2

500

2

3

10

Facing tool

vernier

-

6

turning

lathe

2

500

2

4

5

R.H. tool

vernier

-

7

threading

lathe

10

120

4.5

5

34

Threading

Thread

-

tool

pitch guage

8

Changing

Milling

the job to

m/c

another m/c & fixing

10

-

-

-

-

Chuckkey, mandrel

-

-

9

slotting

Milling

20

250

10

3

60

End milling -

m/c

-

cutter

Part Name

: NUT

Total Time

: 180 min/Nut.

Material

: C15

Quantity

: 16

Sheet No.

:3

Part Name

: BOTTOM FIXTURE

Total Time

: 180 min.

Material

: C15

Quantity

:1

Seq.

Operation

No.

details

Machine

Setting

Spee

Feed

No.

Machining Tools

time(mi

d

(mm/re

of

time(min)

n)

(rpm

v)

cuts

-

-

Gauges

Remar k

) 1

Chucking

Lathe

10

-

-

Chuckk Surfac ey

-

e gauge

2

Facing

Lathe

5

500

2

3

10

Facing

-

-

-

-

tool 3

Turning

Lathe

5

500

2

5

20

R.H.

tool 4

Reversing

Lathe

10

-

-

-

-

the job &

Chuckk Surfac ey

chucking 5

6

7

Facing

Turning

Changing the

-

e gauge

Lathe

Lathe

Lathe

5

5

10

500

500

-

2

2

-

3

5

-

10

20

-

job to

Facing

Meter

tool

scale

R.H.

Vernie

tool

r

Chuckk -

-

-

-

ey

another m/c 8

Fixing on the

Drilling

table

m/c

15

-

-

-

-

‘T’ bolt

-

-

Drill

Vernie

-

bit

r

Drill

-

Nut & spanne r

9

10

Drilling dia.

Drilling

27mm

m/c

Drilling dia.

Drilling

11mm

m/c

5

10

560

560

0.4

0.5

2

4

10

20

bit

-

CHAPTER-9 MERITS AND DEMERITS Merits: 1. It reduces the manual work 2. It reduces the production time 3. Uniform application of the load gives perfect fitting of the bearing. 4. Damages to the bearing due to the hammering is prevented 5. It occupies less floor space 6. Less skilled operator is sufficient

Demerits: 1. Initial cost is high 2. Cylinder stroke length is constant 3. Need a separate compressor

CHAPTER-10 LIST OF MATERIALS PART

MATERIAL

QUANTITY

Pneumatic cylinder

Cast iron

1

DC Valve

Aluminium

1

Flow control valve

Aluminium

1

Top plate

Mild steel

1

Bottom plate

Mild steel

1

Screw rod

En8

4

punch

En8

1

die

En8

1

Hexagonal nut

En8

16

Hose

Polyurethane

3m

Pneumatic connecter

Brass

8

CHAPTER-11 COST ESTIMATION 1. MATERIAL COST: PART

MATERIAL

QUANTITY

Pneumatic cylinder

Cast iron

1

DC Valve

Aluminium

1

Flow control valve

Aluminium

1

Top plate

Mild steel

1

Bottom plate

Mild steel

1

Screw rod

En8

4

punch

En8

1

die

En8

1

Hexagonal nut

En8

16

Hose

Polyurethane

3m

Pneumatic connecter

Brass

8

TOTAL

AMOUNT(Rs)

:

2. LABOUR COST LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING: Cost =

3. OVERHEAD CHARGES The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost =

Material Cost + Labour cost

= = Overhead Charges

=

20% of the manufacturing cost

= TOTAL COST Total cost

=

Material Cost + Labour cost + Overhead Charges

= = Total cost for this project

=

CHAPTER-12 CONCLUSION This multipurpose press is used for pressing stampings, bearing of rotors, removing bend in a shaft etc. So this machine very useful in all industries.

The design of this machine can be improved to reduce further manual work by incorporating the following ideas and attachments.

By incorporating FRL (Filter, Regulator, and Lubrication) unit, the functioning of the machine can be improved. The hand operated valves can be replaced by solenoid valves Limit switches can also be used to get the variable strokes.

BIBLIOGRAPHY

1. Design data book 2. Pneumatic hand book 3. Machine tool design hand book

- P.S.G. Tech. - R.H.Warrning - Central machine tool Institute, Bangalore.

4. Strength of materials

- R.S.Kurmi

5. Manufacturing Technology

- M.Haslehurst.

PHOTOGRAPHY